Building construction



Oct. 22, 1935. H. H. VAN HA-GAN BUILDING CONSTRUCTION Filed Dec. 9, 1929 3 Sheets-Sheet l INVENTOIR 1130mm Homer H. Van H0 07'), BY a H. H. VAN HAGAN 2,018,334

BUILDING CONSTRUCTION Filed Dec. 9, 1929 3 Sheets-Sheet 2 Oct. 22, 1935.

5 R M 4/5 2 5 5 1 m l E m M m Mia m w nx Homer H. V011 Haydn, BY m 44 Z Oct. 22, 1935. f H VAN HAGAN 2,018,334

BUILDING CONSTRUCTION Filed Dec. 9, 1929 :5 Sheets-Sheet 5 INVENTOR Homer H. V011 H494 71 AT ORNEY Patented Oct. 22, 1935 UNiTED STATES PATENT OFFICE BUILDING CONSTRUCTION Application December 9, 1929, Serial No. 412,601

11 Claims.

This invention relates to the art of building construction. It has for an object the provision of an interior construction which is strong and durable, simple of construction and inexpensive of application.

Cellular gypsum has been extensively used in building construction as a poured-in-place insulating material between walls and under floors. The material has also been cast into blocks in the field, and grouted in place between studs or sleepers while still wet. In the latter case the cellular material is designed to be used as a surface or base for the application of plaster coatings and although such a construction is theoretically simple and economical, in practice it has been found quite impractical because the cellular material requires so much time to dry out that subsequent construction operations, such as the application of plaster coatings, are delayed. If the material is not dried out before the application of plaster, the surface of the coating material will become covered with an efilorescence or a powdery crust. This result occurs in cellular gypsum wherein the cellular structure is precipitated by chemical action. Usually carbon dioxide is the bubble-generating gas and during the reaction are formed soluble salts, such as sodium sulphate which are carried to the surface as the moisture of the construction evaporates or is absorbed by the surrounding medium, with the result that it precipitates on the. surface to form the objectionable efilorescence alluded to.

When cellular gypsum is used .as a floor fill, the moisture therein causes the subsequently applied flooring to bulge, unless the fill has been allowed to dry a considerable time. Moreover, this material, especially when used as roof insulation, cannot be applied in winter or in freezing weather because of the difficulty experienced with the cellular gypsum mix during these periods. The modern requirements of rapid construction make it impossible to permit the fioor fill to stand or dry long enough for the cellular gypsum to expel the excess moisture required in the mix, and consequently bulging and warping floors result.

An object of this invention is to eliminate the above mentioned disadvantages, and to retain the normal advantages of this product, such as those of its being light in weight, insulating, fireproof, vermin-proof and capable of forming an efficient base for the application of plaster. By virtue of the invention efflorescence is entirely avoided, floor bulging is eliminated, construction operations are not hampered during freezing weather, and a, uniform plastering surface insulating layer is secured in simple and economical manner.

Another object of the invention is to provide a p-re-cast and pre-dried cellular block construction which can be utilized for walls, roofs, floors and other building needs wherein strong light 5;- weight insulating material is desired.

Other objects and advantages of the invention will hereinafter appear when reference is had to the accompanying specification and drawings, in which Figure 1 is an elevational view of a part of a wall constructed in accordance with this invention, with portions of expanded metal strips being cut away.

Figure 2 is a cross section of a ceiling construc- 15 tion, taken at right angles to the length of the floor beams.

Figure 3 is a modified form of the construction shown in Figure 2, also shown in section.

Figure 4 is a perspective view of one form of 20 fastening means.

Figure 5 is a. perspective view of a pre-cast block which is adapted to be used with this invention.

Figure 6 is a perspective view of a roof con- 25 struction embodying the principles of the invention, and

Figure 'I is a perspective view of a floor construction also embodying the principles thereof.

Figure 8 is a sectional view of a partition con- 3 struction with .a partly applied layer of plaster thereon.

Reference character I illustrates a pre-cast block of material which is adapted to be set in between the vertical studs 2 or floor beams or 3 rafters 2 as indicated in Figures 1, 2 and 3. These blocks are preferably made of cellular material which is capable of forming an eflicient base for the application of plaster. On the faces of the studs 2 are provided fastening means 3 which in 40 the instance typified comprises a plate (Figure 4) centrally provided with an orifice, as shown. Nails or other fastening devices are inserted in this orifice to rigidly fasten each plate in place in the studs or rafters so that each plate extends transversely thereof as indicated in Figure 1. The pro-cast blocks are inserted between the studs and pushed snugly against quarter stripping or grouting means 6 and secured in place by plates 3. Expanded metal strips 5 of conventional type are then fastened over the supporting structure plat/e members so that the surface of the entire structure affords a strong, efiicient and simply constructed base for the reception of a plaster coati As described above, the pre-cast blocks may be made of cellular material, such as cellular gypsum, in which small holes and depressions afford a strong and absorptive base to which plaster will efliciently bond when the same is applied thereto. The invention, however, is not to be limited to a cellular block construction, as

c any suitable material can be used which acts as a value. 7 applied to the surface of the blocks whichpresent base for plaster material. The expanded metal strips form interstices over the relatively smooth studding or beaming into which an applied plaster or plastic coating effectively dovetails. No appreciable extra thickness of plaster is required by this construction as indicated in Figure 2, as the beam coverings are substantially flush with the faces of the blocks.

The blocks, being cast at the manufacturing plant, are well seasoned and dried and are ready for the immediate application of plaster coatings, the efllorescence. having been wiped off before shipment. These blocks can be produced by quantity methods of production and a considerable saving to the contractor or consumer is thus obtained.

Figure 3 illustrates a. modified form of the construction described, in which plates 3 are channelled. 1

In Figure 6 the blocks are set in place and subsequently grouted by filling or grouting material 8 which is preferably of insulating value and whichacts as an expansion joint between them and allows this type of construction to be effectively utilized in roofingfconstruction without danger of cracking and without loss of insulating Roofing material II, is advantageously an efficient bonding surface therefor. 9 designates cast concrete construction of the usual type on which the material constructed and applied in accordance with the invention can be used to advantage. V

In Figure 7 the blocks I are laid on concrete supporting structure 9 between sleepers 1. Grouting material 8' is inserted between the ends or' butts of the blocks and flooring I0 is secured across the sleepers in the usual manner.

7 manner a floor construction of simple and economical nature is secured which is heat, cold and sound insulating, fireproof and vermin-proof, as Well as one wherein there is no swelling of floor boards. f

InFigure 8 the blocks areshown as being made exactly the same thickness as the depth of the studding, so that plates 3 on each side are all that are required to properly hold the insulation in place. V

In addition to, the advantages pointed out above, the construction as herein disclosed providesla complete incasement for wooden structural material such as studs and sleepers, aifords a complete firestop between vertical studding andeliminates interior lathing and sheathing.

There is no moisture in the construction to form efilorescence on the finished coating material and sulation which is made entirely of pre-cast, preno retained moisture in the flooring or roofing indried blocks heldin position by a very light grouting.

provide and to retain in said precast, predried In this 2. A building construction block made fromhydrated calcined gypsum and precast,,set and predried to a predetermined form, said block in said precast, set and predried form having a cellular body structure and providing by exposure of the cells upon the uncut surface in said cast form cellular exterior surfaces for the bonding of surface coatings.

3. A building construction comprising a rigid, self-sustaining supporting structure, and block members having a cellular body structure precast from plastic material and set and predried to a predetermined form to fit to said supporting structure in said precast, set and predried condition, said cellular body structure extending to the surface of said block members to expose the cells upon the surface thereof forbonding of surface coatings.

4. A building construction comprising supporting members arranged to form a rigid selfsustaining structure, and precast, set and predried blocks of plastic material having a cellular body structure, said blocks having a form in said precast, set and predried condition predetermined without cutting thereof to fit between said supporting members and to provide therewith a continuous base for application of a finishing material, said blocks in said uncut, precast, set and predried form providing a cellular surface for said base for bonding of the finishing material.

5. A building construction comprising supporting members providing a self-sustaining rigid frame, block members having a cellular body structure precast from plastic material and set and predried to aform predetermined to fit between said supporting members of the frame and to abut thereto without cutting the body structure of the block-to expose the cells, the exposed uncut faces as cast of the blocks on either side of the supporting member providing with said member a substantially continuous surface for bonding of finishing material, and means for securing said blocks in said frame without substantiallyinterfering with the continuity of said surface.

6. A building construction block made from a plastic material capable of setting and precast, 5

set and predried to, a predetermined form, the

mass of the plastic material in said block in said exposing said cellular structure upon said surface coating.

faces sufficiently to provide for bonding of a sur-,

'7. In combination with a floor or roof supporting structure providing a. substantially continu ous surface, a block of plastic material capable of setting and precast, set and predried to a predetermined form, the mass of the plastic material in said block in said precast, set and predried form being in a condition providing in said block a cellular body structure extending to and exposing the cells upon the surface thereof, said block being so supportedupon said surface of said supporting structure as to provide an insulating layer for said floor or roof structure presenting a surface upon which may be laid a covering.

8. A construction as claimed in claim 7 in which a plurality of blocks of like thickness are laid upon the structure to provide a substantially continuous surface upon which to lay the cover- 9. In combination with a floor or roof supporting structure providing a substantially continuous surface, a plurality of blocks of plastic material capable of setting and precast, set and predried to a predetermined form, the mass of the plastic material in said blocks in said precast, set and predried form being in a condition providing in said blocks a cellular body structure, said blocks being supported upon said surface of said supporting structure and being of like dimension at least in the direction normal to said surface of said supporting structure and being positioned thereon adjacent each other to provide an insulating layer presenting a substantially continuous surface.

10. A construction as claimed in claim 9 in which the blocks are laid in abutting arrangement and the joints between the blocks are grouted with grouting material of a composition providing an insulating quality but being capable of yielding to provide for expansion of said blocks, to prevent cracking and the loss of insulating value thereof.

11. In combination with a floor or root supporting structure providing a substantially continuous surface, a plurality of blocks of plastic material capable of setting and precast, set and predried to a predetermined form, the mass of the plastic material in said blocks in said precast, set and predried form being in a condition providing in said blocks a cellular body structure, said blocks being laid between sleepers and with said sleepers being supported upon said structure to form with the sleepers a substantially continuous surface upon which to lay a covering fastened to said sleepers.

HOMER H. VAN HAGAN. 

